EXERCISE 3: MATERIAL STORAGE AND HANDLING

Course: Shipyard and Engineering Project Management (LGB 42003)

Name : AHMAD KHAIRIL BIN AZMAN

ID : 56211114197

Group : L01

1. Effective material storage and handling may help improve work flow and productivity in

a shipyard. As a shipyard manager you need to store a lot of raw materials such as ferrous and

non-ferrous platings, bars and rods, toxic chemicals such as acids, resins and catalyst, timber and

fiber glass materials in the stockyard of your shipyard. Develop safe methods and procedures for

storage and handling of these materials and discuss the reasons why you choose those methods in

a short report.

2. Your short report should be at least 5 pages, Font 12, Times New Roman, 1.5 spacing, in

English and comply with the standard formatting requirement for a technical report. Submit

your report by next week’s lecture period.

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INTRODUCTION

Handling and storing materials involve diverse operations such as hoisting tons of steel with a

crane; driving a truck loaded with concrete blocks; carrying bags or materials manually; and

stacking palletized bricks or other materials such as drums, barrels, kegs, and lumber. The

efficient handling and storing of materials are vital to industry. In addition to raw materials, these

operations provide a continuous flow of parts and assemblies through the workplace and ensure

that materials are available when needed. Unfortunately, the improper handling and storing of

materials often result in costly injuries.

STORAGE AND HANDLING METHOD

There is various method to storage and handling method that can give safe procedure to achieve

high efficiency to contribute to on going project. Below are method including:

1. Stock Holding Structure

Racks, shelving, bins, hoppers and other structures for the storage of materials should be

adequately designed to support and contain the materials for which they are used.

Allowance should be made for the possibility of stored materials becoming waterlogged,

and for shock loads from placing materials or from accidental contact by handling

equipment. When partitions are used to increase storage capacity, or to separate stored

materials, they should be adequately designed and be of sufficient strength to contain the

stored material safely. Fire-protective partitions should be used between stored items of

differing vulnerability to fire.

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 The corners or ends of shelving and racks should be protected from damage by forklift

trucks or mechanized equipment by steel posts, angle irons or other means.

2. Pallet Construction and Loading

Pallets should be of sound construction and be of adequate strength for the loads and

conditions under which they are used. Where pallet loads are stacked tier on tier, the

lower pallets should be of suitable strength and in good condition and the unit loads must

be able to support the weight above.

3. Positioning of Material

Stacks should not be created where any part will be within 1.5 m of a rail track. This

clearance should be continued all the way along the stack. Stacks, shelving and other

fixtures for holding or storing materials should be so laid out and designed that there is

sufficient access for safe loading and unloading by either manual or mechanical means.

Storage areas should be specifically designated, be clearly marked, and be in the charge

of a responsible employee. Aisles should be clearly marked, be of ample width for the

type of storage, and be kept free from obstacles and waste materials. Stacks should not be

created which will block gangways, aisles, walkways, thoroughfares, and particularly

doors and exits. Stacks or material should have clear spaces of at least 1 m on all sides,

apart from walls, where a 450 mm space should be allowed. Material must not be stacked

within 1 m of the ceiling, roof or sprinkler heads. Base areas and heights of material

should be kept as small as circumstances permit. Material should be kept well clear of

light fittings, heating pipes and appliances, firefighting and alarm equipment, and doors.

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 Drums, casks and cylinders may be stacked on their sides or ends unless

specifically required to stand upright on instructions from their manufacturer or supplier,

such as acetylene cylinders. If stacked on their sides, wedges should be fixed at the ends

of each row to prevent movement. If gas cylinders are stored on end, restraining chains

should be fitted to prevent them toppling. The valves of gas cylinders under pressure

must always be protected. Power-operated clamps on forklift trucks enable cylindrical

objects such as cable drums or pipes to be stacked on end, allowing greater economy of

space and greater stability.

Suitable racks should be provided for steel tubes, bars, joist sections and similar

materials. Large-diameter tubes or pipes can be stacked on their sides, as for drums.

Wedges, chocks, stakes or other means should be used to restrain the bottom tier of round

objects which are stacked or tiered and which could cause the stack to collapse by rolling

or moving. Where successive tiers are not nested but rest on battens, planks or other flat

surfaces, they should be restrained from moving by wedges secured to the battens or

planks.

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4. Segregation of Stock

Flammable liquids, gas cylinders, aerosols, materials liable to spontaneous combustion

and hazardous chemicals should not be stored in the same area as other material.

Chemicals liable to react with each other or other materials should not be stored together

unless adequately protected from contacting each other, either directly or by spillage. The

storage area or building should be signposted to indicate that it contains flammable or

hazardous chemical materials and that smoking and naked flames are prohibited.

Electrical equipment used in or around the storage area or building should be suitably

explosion-protected, and protective equipment should be provided nearby for use in

emergencies. Workers handling corrosive or hazardous chemicals should be provide with

suitable protective clothing, or other necessary safeguards. Liquefied and compressed gas

cylinders should be stored in well ventilated areas, out of direct sunlight and well away

from possible sources of ignition, especially electrical fittings or fuse boxes. All

containers, drums and cans should be clearly labelled with their contents.

Figure 1 Flammable Liquid Storage

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SYSTEM OF STORAGE AND HANDLING MATERIAL

In term of productivity, there are another support party that can help to boost the efficiency of

storage and handling material. One of the system is Pick to Light. In a high-density order picking

warehouse where there are multiple picking locations that require pickers to be fast and accurate,

a “pick to light” or light-directed system can be implemented to enhance the capabilities of the

employee

The basic system will include lights above the racks or bins where the employee will be

picking from. An operator will scan a barcode that is on a tote or picking container which

represents the production order. Based on the order, the system will require an operator to pick

an item from a certain bin. A light above the bin will illuminate with a quantity to pick, the

operator will select the item or items for the order, and to confirm the pick, the operator will

press the lighted indicator. The operator knows the picking for the order is complete when no

further lights are illuminated.

ADVANTAGES OF PICK TO LIGHT SYSTEMS

Some voice-guided systems offer companies the ability to operate the system using different

languages based on the diversity of their warehouse staff. However, the light-directed systems do

not require any language requirements as only numbers are displayed. This allows companies to

have a completely diverse warehouse staff without worrying about issues concerning

understanding the systems voice or any language skill issues. It also allows companies to use

temporary labor during busy seasons to perform picking operations with limited training

requirements.
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A light-guided system will give real-time feedback on order picking and the productivity of the

operator. This reporting can be used to identify a picking issues and how productivity is

improving. Companies that operate pick to light systems report that they can expect over 450

picks to be made per hour by each operator. This is approximately ten times the picks made by a

warehouse operator using a paper-based system. The equipment used in light-directed systems is

simple and can be integrated with a company’s existing warehouse systems (WMS) or enterprise

resource planning (ERP) implementations.

CONCLUSION

The main objective of the efficient materials handling and storage is to decrease the costs.

Materials handling equipment does not come under the production machinery but is an auxiliary

equipment which can improve the flow of materials which in turn shall reduce in production

machines and thus increases their production.